Pumping Unit C-640D-305-168
Pumping Unit C-640D-305-168
Pumping Unit C-640D-305-168
C-640D-305-168
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Table of Contents
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Watch out! …
From this symbol throughout the book. It will direct your attention to
information that involves your safety!
Read and understand all assembly and operating instructions and precautions
before attempting to assemble and operate the pumping unit.
Avoid the possibility of fire when working in the vicinity of an oil well. Be prepared for an
emergency, fire or mechanical failure, in the event that an accident does happen.
The pumping units are constructed of large and heavy rotating parts. When working
around these machines, it is essential that all personnel involved with the installation,
assembly, operation and maintenance of the pumping units use extreme care and good
safety practices at all time. Failure to use extreme care when working with them can
cause severe bodily injury or death.
During assembly of pumping units, a hoisting supervisor should give direction for all
hoisting operations and be located where he is readily visible to hoist /crane operator
and can view all of the hoisting operations. All persons should exercise extreme caution
and stay clear of all objects being hoisted. When working on ladders or work stand,
insure adequate footing and holds to securely assemble the large components.
It should be noted that a pumping unit has components, which can start moving from
the effect of gravity. All personnel should stay clear of the crank and counterweights or
other elements, which may start moving. Times of particular danger from rotating or
moving parts would be during assembly, stroke change, counterbalance change,
general maintenance of any kind. The pumping unit is equipped with a braking system,
but the operator should also devise safety stops from heavy timbers or metal
tubing/channels that can be placed under or against the crank. When the long end of
the crank arm is straight down, no rotation will start when the power source is
disengaged, provided the carrier bar has not yet been attached to the polished rod or
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Attention
Do not operate the pumping unit unless all safety shields and guard rails are
securely fastened in place.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
INTRODUCTION
The purpose of this manual is to provide instruction on the parameter, structure,
installation, assemble, operation and maintenance of a pumping unit. It will provide the
means for a safe and efficient installation and operation. Due to the size of the pumping
unit and its components, safety must be stressed during assembly, at start up and any
time that maintenance is performed. Before beginning assembly, operation or
maintenance, review the safety precautions section.
The date presented in this manual was current at the time of printing. The photos and
illustrations used in this manual may not look exactly like your pumping unit, but are
representative and specify the correct parts and instructions required to properly
assemble, maintain and operate your particular pumping unit. Improvement and parts
change about the product will not be informed; owner/operator should take the material
object as the standard.
These models units (refer to appendix section) are conventional pumping units with
beam balanced. The motive force is furnished in different configurations, depend- ing on
requirements of the customer either the electromotor or natural gas engine.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
The pumping units are designed and rated according to API specifications. This design
and specification calls for the unit to operate at Max.9 strokes (For Type 640D is 8 SPM)
(electromotor configured) or 8 strokes (max) (nature gas engine configured) per minute
and with proper counterbalance adjustment.
Pumping unit direction: Viewed from the side of pumping unit, the horse-head side is the
front of the pumping unit, the motor side is rear. Facing the front of pumping unit, the
side on the right hand is the right side, on the left is left.
Pumping unit rotation direction: the rotation of this type is the direction of the crank
falling to the rear of the pumping unit; or when standing on the left of the pumping unit
and facing to it, the rotation direction is the crank rotating anti-clockwise.
All bolts used on the pumping unit are important. The surfaces under the bolt head and
nut and the contacting surfaces must be flat, clean, and free of burrs so that the bolted
members join in a "metal to metal" contact. Bolts that are properly tightened according
to the manual will retain their grip under normal operating conditions. Improperly
tightened bolts will break in fatigue and may cause serious failures and injury to
personnel. The following table gives recommended tightening torques.
Table 1. Recommended bolt torque values for grade 5 of USA
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Conventional Beam Pumping Unit Operation and Maintenance Manual
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Conventional Beam Pumping Unit Operation and Maintenance Manual
2) Carrier Bar
Carrier bar is used to connect polished rod and wire line, high strength and stability.
4) Horse-head
Horse-head is welded with steel plate. Wire line is hung in the horse-head rope support.
The horse-head connect to front of the walking beam.
5) Walking Beam
Walking beam is welded with steel plate shaped H-section. It is designed according to
the requirement of API APEC 11E and has sufficient strength. The front of walking
beam is connected to horsehead by four horsehead pins or a shaft. There has been
installed cross beam bearing frame at the rear end. Whole walking beam is fixed on
support bearing seat.
6) Samson post
Samson post is welded by section steel. It is fixed on the base by bolts and has
sufficient stability.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
9) Cross beam
Cross beam is made of steel plate by welding. It is according to the requirement of API
APEC 11E and has sufficient strength.
10) Pitman
Pitman is made up of upper connecting rod head, lower connecting rod head and
seamless steel pipe by welding. Upper connecting rod head has shaft sleeve, which has
abrasion resistance to prevent rustiness with connecting rod. Upper head connect cross
beam by connecting rod pin. Lower head is connected with wrist pin and easy to install
and remove.
12) Crank
Crank is made of cast iron. Crank is installed at the two sides of the reducer used
wedge to wedge tightly. Every crank has two differential bolts to lock crank at the
reducer output shaft. There are three wrist pin holes in crank. The wrist pin can be
installed in different hole to get corresponding strokes. There are gear rack and crank
balancing weight in crank. Adjust crank counter weight position through gear rocker arm
to get the best balance efficiency.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Oil level indicator has been installed in reducer box to check oil level. Dipstick slot has
been installed on reducer cover to check oil level by dipstick.
Reducer is installed on base barrel. Draft shaft two ends have installed crank. Input
shaft left-end is mounted with brake wheel and right-end is mounted with big adhesive
tape wheel to transfer dynamic force.
Caution: Reducer middle shaft and draft shaft covers have oil slot. When maintaining
them, pay attention to its position and there should be no oil way plug, otherwise,
bearing will lack lubricate oil to cause destruction of middle shaft bearings and output
shaft bearings.
WARING! Check brake wheel and reducer drive sheave periodically. There
should be no flabby instance occurred.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
16) Base
Base is used to support and fix pumping unit, with sufficient stability.
Note: Base must be sit on concrete foundation, which should steadily sit compaction
ground and pumping unit base has no vibration, otherwise, it might fracture.
Caution: Check bolts periodically to prevent pumping unit from vibrating and shaking.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Consider the local main wind direction to avoid the leaking gas and oil liquid blowing to
the pumping unit and motor. The well field conditions must also be considered in order
to secure enough space for oil service easily.
Notice: Before installation, consider stroke length, carrier bar lower dead point height
and wellhead height enough to make appropriate height concrete foundation. We
suggest that concrete foundation height isn’t less than 350mm (13.78in).
4.1 FOUNDATION
The foundation is prefabricating 200# concrete made from 400# ordinary concrete.
Customer can prefabricate integral or segment foundation to move easily. The
recommended install plans and foundation style please refer to appendix.
The foundation should be positioned in accordance with a foundation plan only. A copy
of this plan may be shipped with the unit. This foundation plan shows the hold down bolt
location in relation to the wellhead, bolt and anchor nut sizes and number. No attempt is
made on the foundation plan to prescribe the shape, depth nor characteristics of the
foundation. The contractor must supply this information based on their knowledge of
and experience with the soil conditions as they exist at the well site and assume full
responsibility for the quality of the foundation.
Foundation tie down bolts must be hammered tightly after concrete has been set up and
pumping unit base alignment is completed.
The bottom of concrete foundation must be filled with gravel. Unsteady foundation may
cause the broken of the unit's base easily.
Levelness of the concrete foundation upper surface should be checked from the front to
rear, right to left and draw out the foundation's central line. The central line shall point
straightly to the wellhead center. Their lateral differential is not over 10mm (0.4in).
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Whether integral or segment concrete, pumping unit anchor bolts must be credible, tight
and take anticorrosive steps. Measure is filled with soil into anchor bolt bore, then seal
with asphaltum.
Review the safety precaution of this manual prior to beginning erection of the pumping
unit.
Step 3: Adjust base levelness. Vertical levelness differential is not over 2.5mm per
meter(≤0.03in/ft)and front is high, back is low. horizontal levelness differential in cross
direction is not over 2.0mm per meter (≤0.024in/ft). upper flat horizontal levelness
differential is not over 1.5mm per meter (≤0.018in/ft)
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Step 1: Assemble the rear leg to the front Samson post, using the bolts furnished. Do
not tighten the bolts securely at this time.
Step 1: Assemble four braces and two support beams to the ladder, leaving the bolts
only hand tightened. Of two support beams, the longer is used at the top of the ladder,
the shorter at the bottom of the ladder.
CAUTION: All bolts should be installed so that the bolt heads are on the inside of the
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Conventional Beam Pumping Unit Operation and Maintenance Manual
ladder.
Step 2: To install the reducer on main base, attach slings or chains to the reducer and
both cranks for proper stabilization. Mark the centerline on top of the base and bottom
of reducer for initial alignment. Place the reducer on drum of base, insert bolts and a
hydraulic screw down.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Step 3: Set the cranks down to a safe position. Remove the chains from reducer but
not cranks. Disengage the brake lock-out and clear the crank sweep area. Slowly
release the brake lever to allow the cranks to rotate to bottom dead center. The chains
may now be removed from the cranks
Step 4: Measure the distance from each end of the crankshaft to the alignment mark. If
they are not equal, adjust it, then Tighten all bolting on gear reducer and bolting on
sub-base.
Step 3: Tighten the nuts and adjusters bolts for proper adjustment.
Step 1: Connect one end of the vertical rod to the bell crank and secure it with the
adjusting rod nut.
Step 2: Loosen the lock nuts and adjust the vertical
brake rod length so that the bell crank is horizontal
when the brake pads contact the hub.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Step 5: Adjust the length of the horizontal rod between the bell crank and the brake
handle so that the cam is approximately horizontal when the brake handle is in the
forward position.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Step 1: Position the equalizer on the ground so that the equalizer bearing housing bolt
holes are on top of the beam.
Step 2: Select the pitman arm which has the lubrication line attached to it(if configured).
Note the position of the lubrication line on the equalizer. Two sets of lubrication lines are
assembled on the same side.
Step 3: Equalizer holes should be cleaned thoroughly before inserting upper pitman
pins in housings. Pitman pins should be covered with anti-rust grease.
Step 5: Connect the lubrication line from the pitman arm to the equalizer (if configured).
Step 6: Attach and assemble the other pitman member according to the same
procedure.
4.10 INSTALLATION OF WALKING BEAM TO EQUALIZER
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Step 2: Lift the walking beam and position the center of the beam on the center bearing.
Insert the bolts and loosely tighten.
Step 2: Install the bolts in horse head to secure the wire line Assembly.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Step 3: Position the carrier bar so that it is relatively straight with the open end facing
the polish rod.
Step 2: Position the center bearing housing on the top of the Samson post. Insert the
bolts and hand tighten
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Step 4: Attach one of flexible hoses on the Samson post to the center bearing, the
other flexible hose to the walking beam.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
a) After erection of the unit is complete, the following checks must be carried out:
b) Check if the foundation is steady and solid.
c) Check and fasten all anchor bolts.
d) Check all the lubricating points to ensure all of them have been lubricated very well.
e) Check all the connection parts to ensure all of them have been connected well.
f) Check driving belt, the tension should be proper.
g) Check brake, it should be flexible and reliable.
h) Check if the installation of electrical circuits and appliances abide by technical and
safety requirements.
i) Check the unit if there are external substances hindering the running of the unit, if
does, clean all.
j) Check the belt-guard (if confined) and ladder to ensure all of them are fixed firmly.
k) Pay special attention to that if the lock dog of the unit's brake safety system has
been lifted and the brake has been loosening.
a) Start the pumping unit; five minutes later brake the unit and check if the wires is
tortuous in running, adjust it.
b) Carrier bar should be horizontal and have no incline and no bending, otherwise,
adjust it.
c) Tension of driving belt should be proper, not too tense or any sliding, otherwise,
adjust it.
d) Horse-head should not have any vibration in running.
e) Samson Post shouldn't have any oscillation in operation.
f) The reducer shouldn't have any oscillation in operation.
g) The prime mover shouldn't have any abnormal sound in operation.
h) Brake should be flexible and reliable.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
i) Check all the connection bolts ensure all of them are fixed firmly.
j) After you have done all the above, please dislodge the safety measures and restart
the prime mover.
Listen for unusual noises. If any occur, locate cause and take necessary corrective
action.
Apply brake slowly several times to be sure it is functioning properly before using it
position cranks.
Stop prime mover and slowly apply brake to stop pumping unit with cranks
horizontal toward well.
When brake holds cranks without slippage, release brake solely and allow cranks to
re-position themselves in the DOWN position .If prime mover is electric, be sure
master switch is locked out. Chain or block cranks to prevent their movement.
Clamp of well at stuffing box.
Danger! Do not work on or near cranks or counterweights until they are chained or
blocked to prevent their movement. Serious injury or death could occur if you do so.
Check all bolts including hold down clamp bolts for tightness.
Re-check alignment to make sure that wire line tracks horse head properly.
Remove chains or blocking from cranks, remove wellhead clamp at stuffing box, release
break and start prime mover to resume pumping.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Listen for unusual noises. If any occur, locate cause and take necessary corrective
action.
Apply brake slowly several times to be sure it is functioning properly before using it
position cranks.
Stop prime mover and slowly apply brake to stop pumping unit with cranks horizontal
toward well.
When brake holds cranks without slippage, release brake solely and allow cranks to
re-position themselves in the DOWN position .If prime mover is electric, be sure master
switch is locked out. Chain or block cranks to prevent their movement. Clamp of well at
stuffing box.
Check reducer oil level. If the level is low, remove the inspection cover and add oil to the
proper level.
Visually inspect the structural bearings for oil seal leaks. This would include the crank
pin, equalizer and center bearing assemblies. Grease fittings are located at ground level,
and if needed, the grease should be pumped in slowly to avoid pushing out the oil seals.
Check all bolts including hold down clamp bolts for tightness.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Remove chains or blocking from cranks, remove wellhead clamp at stuffing box, release
break and start prime mover to resume pumping.
Before do the maintenance for the pumping unit, you must obey all the safety
specifications mentioned above.
It is recommended that an oil sample be taken every six months to determine condition
of the oil. Collect a typical sample of the reducer oil in a transparent receptacle. A visual
inspection will expose possible dirt, sludge, water emulsion, or other forms of
contamination. You may also desire to determine that you have any of the following
conditions in the lubricant, check with a qualified vendor regarding replacement:
a) An acid or singed odor indicates oxidation of the oil to the degree that it should
be replaced.
b) If sludge is observed in the used sample, the oil should be replaced or filtered to
remove the sludge. This condition is prevalent if the lubricant has not been
changed for a long period of time.
c) If water exists in the used sample, the water should be completely drained from
the reducer. Subsequent bubbling will occur with as little as 0.1% of water
present in the oil. If there is greater than 0.2% water by volume, an oil change is
recommended.
Visually inspect the wire line for wire fraying. A rusty wire line should be cleaned and
coated with a wire line lubricant as specified in the manual.
Belts’ alignment and tension should be checked and adjusted to prolong their life. Under
normal utilization belts will stretch and wear. It is recommended that new belts be
retightened after the first 24 hours of operation.
Check all bolts. Retighten all bolts according to the table 1.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Efficient operation, torque loading, and maximum life of a pumping unit are all
dependent on the proper counterbalance. Counterbalance requirements can be
determined very accurately or estimated by various methods.
A dynamometer card analysis is the most accurate method for determining loading and
counterbalance. This involves using a dynamometer to record the well load through a
stroke cycle and then using torque factors to determine the reducer torque and
counterbalance required for balanced conditions.
2) Ammeter:
A clip on ammeter may be used to compare the up-stroke and down-stroke current on
electrically powered units. When the counterbalance is adjusted so that the current
peaks are equal, the unit will be roughly in balance.
3) Vacuum Gauge:
A vacuum gauge may be used to compare torque peaks on engine driven units much
similar the ammeter is used on electrically driven units. Vacuum pressure decreases as
engine output increases.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
5) Belt Tension:
Belt tension and subsequent belt stretch increases with load. This causes a proportional
amount of slack in the belts on the side opposite the direction of rotation of the prime
mover. A visual inspection of the belt sag on up stokes or down stoke, can be used to
estimate counterbalance.
6)Counterweight Adjustment
Rotate the unit and apply the brake so that the crank is slightly downhill in the direction
that the weights are to be moved. Set the brake, engage the brake lockout bolt or pawl,
and secure the cranks against rotation. Loosen the counterweight bolts just enough to
allow the weights to be moved. Use the pinion adjusting wrench to move the weights to
the desired position. It is important to note that larger weights may have to be moved
with the aid of a crane or a pry bar. The weight on the crank may be moved in a similar
manner. After positioning the weights in the desired location, tighten the counterweight
bolts utilizing recommended levels of tightness, and add a second nut for a jam nut.
Locate the cranks at approximately the 2 o'clock position and set the brake. Place a
polished-rod clamp at the stuffing box and tighten according to the clamp
manufacturer's recommendations. Using the prime mover or a crane-lift, relocate the
cranks to the 12 o'clock position and set the brake.
You may now disconnect the carrier bar from the polished rod. Insert a long chain
through the carrier bar and install the gate back into the carrier bar. Hold the end of the
chain and pull the carrier bar away from the polished rod while slowly releasing the
brake and letting the cranks down to the 4 o'clock position.
Always disconnect or lockout the prime mover. Remove the crank guard side panel to
gain access to crank area, secure the unit against rotation by the brake lock out bolt or
pawl. Place one 1-1/2 ton come-a-long between the carrier bar and the front
cross-member of the base. Place another between the equalizer and the holes on the
front of the sub-base. Tighten both come-a-longs to restrain possible movement or tilting
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Conventional Beam Pumping Unit Operation and Maintenance Manual
of the walking beam that will occur once the crank pins are removed from the cranks.
Remove the cotter pin and then remove the crank pin nut using the box end hammer
wrench (furnished as an option), and a minimum 14 pound sledge hammer with a full
length handle. Drive out the crank pin using a drive nut and tools above. The drive nut
(furnished as an option) is screwed on until it bottoms on the end of the pin. Hammer
against the head of the drive nut until the pin is loose. If a drive nut is not available, it is
recommended that the hammer hit as squarely on the end of the pin as possible to
prevent surface damage. Once the pin becomes loose, do not remove it from the hole.
Remove the drive nut and install the original nut three or four threads deep. This
procedure should also be used on the opposite crank pin.
Check the crank pin clearance in the hole and adjust come-a-longs accordingly so that
when the pins are removed they will not fall nor pull up in a sudden motion. Remove the
nuts and pull the crank pins out of the crank holes. The pitman side members will
support the crank pin bearing assemblies until the pin is installed into another hole. It is
recommended that rust preventive be applied to the crank pin bore after the pin is
removed.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Step 5: Using a sledge hammer on the wrench, turn the nut two cotter pin notches past
the hole in the pin and line up the hole in the pin with the third cotter pin notch. Install
the cotter pin. Never back the nut off to insert the cotter pin. If you have turned the nut
too far, remove the crank pin and repeat all of the installation procedures.
With the brake engaged, remove the come-a-longs, unchain the drum and disengage
the lock out bolt or pawl.
Hold the carrier bar away from the polished rod with the chain and slowly release the
brake to let the cranks go to the bottom. Engage the prime mover (or crane) to slowly
reposition the cranks at 12 o'clock while holding the carrier bar away from the polished
rod. Remove the chain from the carrier bar and attach the carrier bar to the polished rod,
please note that the bottom hole pump spacing will need to be checked and the
polished rod clamp may have to be repositioned to accommodate the new stroke length.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Slowly release the brake to transfer the well load back to the carrier bar. Make certain
that the load isn’t on the polished rod clamp at the stuffing box. If necessary, use the
prime mover to lift the load. Remove the polished rod clamp at the stuffing box that was
used to clamp off the well load.
It is important to note that after a stroke length change, the counterbalance should be
checked and repositioned for the proper balance.
ADJUSTMENT CALCULATION
Pumping unit equilibrium directly influences reducer and motor load, life and whole
machine running stability. So before erecting the pumping unit, preliminary equilibrium
should be calculated and adjusted according to the situation of the oil well and the
pumping unit, in order to avoid the serious non-balance when the pumping unit working.
After pumping unit put into production, adjust equilibrium according to crankshaft actual
torque to assure pumping unit operate in the best condition.
Before erecting the pumping unit, preliminary equilibrium should be calculated and
adjusted according to the situation of the oil well and the pumping unit, in order to avoid
the serious non-balance when the pumping unit working.
Note:
MBlance, balance torque (N.m);
Pr o ,d weight of the sucker rod inside oil (N);
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Conventional Beam Pumping Unit Operation and Maintenance Manual
, weight of the oil column on the sectional area of the oil pump plunger
POil
above the dynamic liquid level (N);
G , weight of the construction non-balance (N);
S , length of stroke of the pumping unit (m);
TF 75°, factor of the torque when crank angle of the pumping unit is 75°(m);
Pmax, the maximum load of the landing top (N);
Pmin, the minimum load of the landing top (N);
MUp max , the maximum moment of torsion between the load of the up-stroke
landing top and the crank axis (Nm);
MDown min , the minimum monument of torsion between the load of the down-
stroke landing top and the crank axis (Nm);
Besides:
=q' L= PS(1-r/7.85)=qL(1-r/7.85)
Prod ④
P'Oil = r³L'³F³g³1000 ⑤
Pmax and Pmin can be read from relevant documents, or calculated according to the
experience formula or the following formula.
+ Prod ³(1+ S ³ N 2 /1790 )
Pmax = POil ⑧
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Or,
+ Prod
Pmax =( POil )³(1+aUp/g) ⑩
³(1+7.85/(7.85-r) ³aUp/g)
Pmin = Prod ⑾
Note:
N , stroke frequency of the pumping unit (L/min);
aUp , the maximum acceleration of the landing top up-stroke.
Note:
WWeight , weight of single counterweights (N)(refer to appendix);
n p , the amount of the counterweight in general, 4 or 2 pieces.
b. According to counter weight position and distance mark on crank
Gravity center of counter weight is situated at the cross of the two vertical connecting
lines between three hoisting bores and one safety locking segment bore. When install,
gravity center is pointed by safety locking segment bore. Gravity center of counter
weight refer to figure 2 .
Counter weight assembly barycenter position: one counter weight position is its gravity
center; two counter weights position is the connecting line center of the two counter
weights gravity center (or connecting line center of the two counter weight safety
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Conventional Beam Pumping Unit Operation and Maintenance Manual
At the crank rack bar, cast scale marks has ―0.5、1.0、1.5‖ to show that the distance
between scale marks and crank shaft bore is 0.5m(19.69in) , 1m(39.37in), 1.5m
(59.06in).
Note: some factory use ―△‖ to point scale marks to show counter weight position.
Counter weight position is according to factory explanation.
After beginning to work, the pumping unit must be confirmed non-overload and
well-balanced. Examination of the pumping unit balance, power balanced method,
torque moment balanced method or current balanced method can be all used.
For example, the current balanced method means when unit has its balance been
adjusted, the maximum different current value between the up-stroke motor and the
down-stroke motor of the pumping unit should be confirmed to be no more than 15% of
the maximum current. That is : current balanced rate, ≥85%:
| IUp max-I Downmax |
(1 ) 100% 85% ⒁
I max
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Note:
, current balanced rate of the motor;
IUp max , the maximum current of the up-stroke motor (A);
I Down max , the maximum current of the down-stroke motor (A);
I max , the maximum current of the motor when the pumping unit rotate on
circle (A).
After the pumping unit begins to work, the balance should be exactly adjusted within 48
hours. When the work factor of the pumping unit adjusted, the balance should be
exactly adjusted at once.
According to the pumping unit working condition, oil well pump and pumping rod, the
balance should be adjusted in order that the pumping unit should work under the best
balance condition. Now we can adjust and calculate according to the following two
methods:
M I I
m ZX Up m a x Do w mn a x
⒂
QWeight IUp m a x+ I Do w mn a x
Note:
mZX , distance that the assembly gravity center of the crank counterweight
should move in order to reach to the balance (m);
mZX >0 meaning that the assembly gravity center should depart from the
crank axis center to moving outside;
mZX <0 meaning that the assembly gravity center should move to the crank
axis center.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Note:
Mn max , the maximum net torque of the crank axis;
M X , effective counterbalance torque (N.m).
Pmax and Pmin have the same meaning as the above, but Pmax and Pmin should be
obtained from the indicator diagram in the near future.
Note: The current method has its limits. When pumping unit is imbalance seriously,
that is, one of the IUp max or the IDown max is motor generated feedback current, this
formula can’t be used.
When IUp max<0, move the counter weight to the crank shaft center closely; When
IDown max <0, move the counter weight to the crank shaft center far away;
When IUp max>0 and IDown max >0, according to current method to calculate
accurately.
Two recommended ways can be used to judge motor’s feedback current in up-ward or
down-stroke approximately.
The 1st way: if panel box has installed watt-hour meter, see if the watt-hour meter
aluminous pan reverse in up-ward stroke or down-stroke max current. If reverse, there
is feedback current.
The 2nd way: when the pumping unit max current in upward stroke or down stroke,
listen to motor sound and see motor rotate speed, if the rotate speed has exceeded
rated value, there is feedback current.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Mw = TF ³( W - G ) ⒆
Tn= TF ³( W - G )- M ³ sin ( ) ⒇
Note:
Mw, torque of the polished rod (N.m);
Tn, net torque of the reducer (N.m);
TF , factor of the torque, the crank angle ;
W , the load of the landing top, the crank angle ;
M ,the maximum torque of the rotation counter weight N.m;
, crank angle of rotation (°);
τ, phase out crank angle;
, the observer should stand in the left of the pumping unit and face to the pumping
unit, and the well head is in the right of the observer, it is the crank angle per clockwise
direction rotation and started from the 12:00 clock place.
Tn, calculating result see table 2 (that is: calculating sheet of the net torque of the
reducer).
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Note:
Tn TF (W G) M sin
Where:
Tn =Net reducer torque. In .lbs TF =Torque factor at .in.
=Position of crank. CG at 270 degrees=___________________
M=maximum moment of counterbalance. In .lbs
M=(CG at 270 degrees-G ( TF at 270 degrees))=_____________________
W=measured polished rod load at . lbs.
G=unit structural unbalance. lbs.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Step 2: draw the curve graph of the net torque after calculated according to the formula
15 and table 2, the Mn - and Mw - curve graph of the net torque should be
drawn.
Note:
M Blance , balance torque (N.m);
Up , crank angle corresponding to MUp max ;
Down , crank angle corresponding to M Down min ;
MUp max and M Down min same to the before-mentioned, that is to say, they can be
obtained through calculating indicator diagram of work in the near future and
reading max in the up-ward stroke , down-stroke on Mw-θcurve graph of the net
torque.
Step 5: calculating the place of the gravity center of the counter weight ( Z X )
Z X can be calculated according to the formula 12.
According to Z X to adjust pumping unit balance. If the balance rate can’t reach
100%, MUp max may be bigger than M Down min .
Calculating the net torque of the reducer, the balance rate Blance should be more
than 85%:
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Note:
Blance ,balance rate, Blance ≥85%;
Mn Up max, the maximum moment of torsion of the up-stroke reducer (N.m);
Mn Down min ,the minimum monument of torsion of the down-stroke reducer
(N.m).
9
1 in=0.0254 m=25.4 mm 1 ℃= °F+32
5
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Conventional Beam Pumping Unit Operation and Maintenance Manual
All structural bearing assemblies and the gear reducer are designed to provide years of
trouble-free service, if proper maintenance are observed by the user at recommended
intervals. Many factors govern the lubrication requirements and maintenance practices,
with some factors peculiar only to certain areas due to type of terrain, prevailing weather
conditions and type of production. The information contained herein may not completely
satisfy the necessary requirements of all pumping units, but if strictly observed as to
lubrication points and type of lubricants, unit downtime will be minimal. Lubricants and
time intervals specified are formulated on normal use of pumping units. If unit is used in
extreme environmental conditions, with exceptional heavy loads or excessive speeds,
time intervals between servicing may need to be adjusted. Lubricant types
recommended may also require change to assure continued satisfactory operation.
The unit's lubricating sites and requirements refer to figure 3 and table 3.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Note: to use grease to lubricate, add lubricating grease every half-year. Avoid adding oil in winter.
1) Before changing the lubricating oil of the reducer, oil should be discharged and
completely flushed with oil solvent. After flushed, solvent should be discharged, and then
flushed again with a little of lubricating oil. After the flushing oil discharged, new
lubricating oil should be put in at once.
2) After having changed lubricating oil, don’t run the pumping unit at once, the reducer
should work at least 10 minutes to confirm to cover a oil layer of maintenance in the
surface of the reducer gear.
1) Reducer lubricating oil level should be in upper lever and lower level. Low oil level can
lead to gears and bears bad lubricating. High oil level can lead to reducer oil leak.
2) At the back of reducer, there are two screw holes, which show the upper and lower oil
level.
Note: Crank pin bearing, cross beam bearing and center bearings assemblies are all
have been lubricated at the factory; however it is recommended that all bearing
assemblies be rechecked for proper grease prior to starting unit. Using approved grease;
pump the grease into each bearing assembly until it overflows through the relief fitting
located in the bearing cover plate. Always pump grease in slowly to avoid damage to the
oil seals.
In addition, hanger screw jack, horse head pin, connection rod pin, brake safety
assembly shaft, brake level pin and so on should be added lubricating oil to rust
prevention or make some of them rotate agilely.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
SAFETY STOPS
To prevent accidental injury to nearby persons, install safety devices to
prevent movement of crank arms or walking beam.
The unit may have some problems during its running; you can locate the cause and take
necessary corrective actions according to the table 4.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Continued with
Troubles Cause Troubleshooting
1.The steel cable has lacked grease and
Add lubrication grease
dried
The wire line
2. Parts of the steel cable has been
abnormally works Change wire line
broken
3. The wire line cap has been loosen Change wire line
Steel cable twist
Carrier bar not The steel cable is not properly adjusted. Adjust the steel cable
straight.
Connection of Carrier 1.The size of polished rod clip and
Replace the polished rod clip
bar and polished rod polished rod un-matching
loosed 2. Polished rod clip worn. Change the polished rod clip
1.The wire line failure Refer to wire line failure section
2. There is friction between wire line and
Adjust walking beam or Samson post or base
the said plate of the horse head
3.The pin of the horse head has been
Horse-head Tighten up it
loosen
abnormally works,
4.The pin of horse head has been worn Change it
vibrating and having
5.The weld joint of the horse head has
noise Repair or change horse head
been broken
6.The said plate of the horse head has
Repair or change horse head
been broken
7.The horse head has sloped Adjust walking beam or Samson post or base
1.The bolts of center bearing seat are Adjust the walking beam, and make the deviation
loosen of the suspending point's projection with center
Walking beam was line of well head be less Ф18mm(0.7in), adjust
displaced or deviated the place of the walking beam, tighten up the
breadth wise. 2.The bolts of center shaft seat are bolts of the center bearing seat, tighten up the
loosen bolts of the center shaft seat, tighten up pulling
3.The pulling bolts of center shaft seat bolts of center shaft seat
are loosen
1.The bearing is worn Change the bearing
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Continued with
Troubles Cause Troubleshooting
Pitman can’t rotate Pitman pin has been rusted Add lubrication grease
1.The bolts which connect Samson post
Tighten up the bolts
and main base are loosen
The Samson post Use the plumb bob to adjust the deviation of the
vibrates, wave center of the beam and the marking hole of the
seriously or has 2. The Samson post un-compact main base is less 5mm(0.2in), add the gasket
position leaning, under the connection board of the supporting
frame, tighten up the bolt of the Samson post.
3.Base failure Refer to base failure section
1.The bearing is worn Change the bearing
Tail bearing
2.Lack of lubrication grease in the bearing
abnormally works and Add lubrication grease
of the seat
having abnormal noise
3.The bolts of the bearing cap are loosen Tighten up the bolts
1.Ential bolts of the crank (the axle of the
Crank runs reducer and the locking bolts for the crank Tighten up the bolts
hole) are loosen
abnormally, loses its
2.Wedge key has been broken Change it
speed or vibrates or 3.The key-slot of the input shaft of the Use another key-slot of the input shaft reducer
jumps reducer has been broken
4.The key-slot of crank broken Change crank
1. Pumping unit is overloaded. Operate the pumping unit according to manual.
2.Insufficient load Operate the pumping unit according to manual.
3. Stork frequency is more than usual. Operate the pumping unit according to manual.
4. Pumping unit is unbalanced. Adjust the pumping unit to balance.
Crank pin works
5. Connection rod is interfered by crank Adjust the position of the pumping unit or adjust
abnormally.
pin. the assemble position between connection rod
Periodic noise from
and crank pin. The difference distance between
crank pin.
each connection rod inside and crank processed
Crank pin displaced
surface must be less than 3mm(0.12in).
on axial direction.
6. Crank pin and crank pin hole is not Check the cone surface of crank pin and crank
mated tightly. pin jacket. If they are worn, change them.
7. The mated surface between Crank pin Clean the crank pin, the crank pin cone jacket
and crank pin hole is not clear. and the crank pin hole.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
Continued with
Troubles Cause Troubleshooting
8. The nuts of crank pin are loosening. Tighten the nuts, install the nuts cover sheet and
loose-proof steel sheet, tighten loose-proof bolts,
bend loose-proof steel sheet to against the bolts,
tie loose-proof iron line.
9. Left-hand thread and right-hand thread Left-hand thread crank pin should be installed at
crank pins are installed incorrectly. the left side of pumping unit. Right-hand thread
crank pin should be installed at the right side of
pumping unit.
1. Lubrication oil is insufficient. Check lubrication oil level and add more
Gear reducer's lubrication oil
bearings are over hot 2. There is friction on bearing cover or Check and adjust sealing part and tighten the
or noisy. sealing part. belts on bearing cover.
3. Bearing is worn. Change the worn bearing.
1. Pumping unit is unbalanced. Adjust the pumping unit to balance.
2. There is friction on bearing cover or Check and adjust sealing part and tighten the
sealing part. belts on bearing cover.
Abnormal noise in 3. Bearing clearance is too big or too Adjust bearing's clearance.
gear reducer, or small.
reducer shocking. 4.Surface of reducer gear is worn. Change gear or gear shaft.
5. Helical gear key slot is loose. Disassemble and repair.
6. Reducer inside shaft is loosely mated Change reducer.
with gears and displaced.
1. Too much lubrication oil. Discharge some oil and situating oil level to
Reducer leakage
stipulated position.
2. Belts connecting reducer up body and Tighten the belts evenly.
down body are loose.
3. Reducer up body and down body Open reducer cover and clean connecting
connecting surface is not bonded or surface. Paint sealing gum on the connecting
sealed. surface evenly, then close the cover and tighten
Reducer leakage box belts evenly.
4. Oil discharge plug or oil level plug is not Tighten the plugs.
twisted tightly.
5. Bearing cover is not pressed tightly. Tighten bearing cover belts.
6. Bearing sealing ring is worn. Change bearing sealing ring.
7 Oil returning hole is blocked. Ball out the oil return hole.
1. Reducer is over loaded. Operate the reducer according to manual.
Gear surface is worn. 2. Pumping unit is unbalanced. Adjust the pumping unit to balance.
Gear has continuous 3. Lubrication oil is insufficient. Add more lubrication oil to the stipulated level.
spot corrosion or has 4. Lubrication oil is improper type. Change it with proper type oil.
been scratched. 5. Lubrication oil is deteriorated. Discharge all used lubrication oil, clean the
inside of reducer and add in stipulated oil.
Continued with
Troubles Cause Troubleshooting
Reducer gears and Lubrication oil has been contaminated by Clean the inside of reducer and change
bearings are worn abrasive substance. lubrication oil.
rapidly.
1. Lubrication oil has been used for a long Change lubrication oil.
Sticky and insoluble time.
sediment on reducer
gears and bearings 2. Lubrication oil has been contaminated. Change lubrication oil.
surface. 3. Lubrication oil is not the proper type. Change it with proper type oil.
1. Discontinuous running under humid Add corrosion inhibitor into lubrication oil.
circumstance.
Gear and bearing of
2. Water is in reducer box. Discharge the water.
the reducer is rusted
seriously and corroded 3. Lubrication oil is not the proper type. Change it with proper type oil.
extensively.
4 Lubrication oil is deteriorated. Change lubrication oil.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
5. The inside of reducer can’t be Clean and ball out the breather hole.
ventilated well. Breather hole was
plugged.
Reducer heated and 1. The quantity of lubrication oil is much Add or reduce lubrication oil to stipulated level.
temperature of oil in oil more or less than stipulated.
sump is more than 60 2. Lubrication oil is not the proper type, or Check and change the lubrication oil.
0
C. lubrication oil is deteriorated.
1. The viscosity of lubrication oil is too Reduce the viscosity of lubrication oil or change
Difficult to start the
high lubrication oil.
reducer in winter.
2. Lubrication oil is ineffective. Changer lubrication oil.
1. Brake clearance is not adjusted Adjust brake clearance.
properly.
Pumping unit can't be
braked or brake 2. Brake block is worn. Change brake block.
automatically.
3. There is oil filth between the brake Get rid of the oil filth.
block and brake drum.
1. The fixed bolts of the motor are loose. Fix the bolts.
Inhomogeneous noise 2. Motor bearing is short of lubrication oil. Inject lubrication oil.
of the motor
3. Motor bearing was worn. Change motor.
1. Belts are lengthened evenly. Adjust motor center.
Belts are loose or 2. The length of belts is different. Use the belts with the same length.
sliding.
3. The fixed bolts of the motor are loose. Fix the bolts.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
If pumping unit accident occurs in the period of guarantee, we provide the following to
quality:
We made a period of guarantee that is from pumping unit leave factory 60 months, and
in the period of guarantee we warrant that the goods under normal operating condition
will be free from repairing.
We are responsible for only to pumping unit and don’t indemnify to other and any bodily
injury.
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Conventional Beam Pumping Unit Operation and Maintenance Manual
In the period of pumping unit leaving factory 12 months, if the following parts or(and)
accessories damages or(and) wear abrasion occur, they will be free and supplied by
manufacturer:
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Conventional Beam Pumping Unit Operation and Maintenance Manual
TECHNICAL SPECIFICATIONS
In this section, Technical specifications and configurations of pumping units are shown in
attached table. It provides a reference for users someway.
When verifying or(and) adjusting unit balance, stroke & torque factors are commonly
referred. Stroke factors & torque factors are shown in this section .
For the convenience of installing pumping units, manufacturer have given some guide for
users, these are sketches of installation of main base and concrete foundations.
For wide-skid, recommended installation plans and concrete foundation styles haven’t
been presented in this manual. If users desire, manufacturer would send similar
information for them in some way availably and timely.
If you have any problems or advise in the unit’s erection, operation or maintenance,
you can contact the manufacturer or the agent.
51